Method for making an apertured web

ABSTRACT

The present invention relates to a method for making an aperture web, comprising moving a micro-textured web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web. 
     The present invention also relates to a method for making an aperture web, comprising forming microtextures on a web, and continuously moving the web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web.

FIELD OF THE INVENTION

The present invention is directed to methods and apparatuses forimparting a three-dimensional structure to web materials.

BACKGROUND OF THE INVENTION

Webs, such as thermoplastic films, have a variety of uses includingcomponent materials of absorbent articles (such as topsheets andbacksheets), packaging (such as flow wrap, shrink wrap, and polybags),trash bags, food wrap, dental floss, wipes, electronic components, andthe like. For many of these uses of webs, it can be beneficial for theweb to have a textured, three-dimensional surface which can provide thesurface of the web with a desirable feel (e.g., soft, silky), visualimpression, and/or audible impression, as well as one or more desirableproperties such as improved fluid handling or strength.

One of approaches to endow a desirable feel to webs is formingmicrotextures such as protrusions and recessions in the webs viatechnologies such as a vacuum forming process, hydroforming process andembossing process. With a typical vacuum forming process, a precursorweb is heated and placed over a forming structure. Then a vacuum of airforces the precursor web to conform to the texture of the formingstructure. With a typical hydroforming process, a precursor web isplaced over a forming structure and high pressure and high temperaturewater jets force the precursor web to conform to the texture of theforming structure.

Micro-textured webs can be further deformed to have three-dimensionallymacro aperture fluid transportation structures. Macro-apertured webs areutilized in a wide variety of industrial and consumer products. Forexample, apertured webs are known for use in disposable absorbentarticles such as disposable diapers and feminine hygiene articles suchas sanitary napkins, and the like. Such articles typically have a fluidpervious topsheet, a fluid impervious breathable backsheet, and anabsorbent core disposed between the topsheet and the backsheet. Anapertured web can be made to form a fluid pervious topsheet and/or thefluid impervious breathable backsheet.

US 2006/0087053A1 discloses a method for making apertures in a precursorweb by moving the web material through a nip of two counter-rotatingrollers, wherein a first roller comprises a circumferentially-extendingridges and grooves, and a second roller comprises teeth which aretapered from a base and a tip, and the teeth are joined to the secondroller at the base. The base of the tooth has a cross-sectional lengthdimension greater than a cross-sectional width dimension.

Even with formation of macro apertures for fluid transportation in amicro-textured web, there still is a challenge in fluid drainage asthere are flat areas in the web. Especially when microtextures are inthe form of discrete extended elements like protrusions, fluid istrapped in valleys among the discrete extended elements. In addition,discrete extended elements are rather fragile, once micro-texturing iscompleted, it is difficult to create apertures by mechanical deformationsuch as hot roll as the heat from the hot roll may melt parts of thediscrete extended elements and impart permanent deformation into thediscrete extended elements, or harden parts of the discrete extendedelements which results in plastic and abrasive feels. For example, theheat can cause end edges of discrete extended elements crisp to becomevery stiff as a result of the exposure to the heat. The crisp orstiffened edges make final products using the web such as absorbentarticles rough to the skin.

Therefore, a need exists for apparatuses and methods that capable ofmechanically forming macroscopic apertures in a micro-textured webproviding an improved fluid handling. A further need exists forapparatuses and methods that capable of mechanically forming macroscopicapertures in a micro-textured web without compromising, even withenhancing desirable softness.

SUMMARY OF THE INVENTION

The present invention provides a method for making an apertured webcomprising moving a micro-textured web through a first member comprisingmale elements and a second member comprising discontinuous femaleelements, wherein the male elements are arranged in a staggered pattern,and have a shape to form quadrilateral apertures in the micro-texturedweb.

The present invention also provides a method for making an apertured webcomprising forming microtextures on a web, and continuously moving theweb through a first member comprising male elements and a second membercomprising discontinuous female elements, wherein the male elements arearranged in a staggered pattern, and have a shape to form quadrilateralapertures in the micro-textured web.

The present invention also provide a method for making an apertured webcomprising moving a micro-textured web through a first member comprisingmale elements and a second member comprising discontinuous femaleelements, wherein at least one of the first member and the second memberis heated, and wherein the first member and the second member have aclearance between a top surface of the second member and a bottomsurface of the first member when the first member and the second memberare in maximum engagement so that the discrete extended elements aresubstantially intact from heat-induced damages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a process of the presentinvention.

FIG. 2 is a view of intermeshing engagement of portions of an apparatusshown in FIG. 1.

FIG. 3 is a cross-sectional representation of a portion of the apparatusshown in FIG. 2.

FIG. 4A is a view of a portion of a first member of the apparatus shownin FIG. 2.

FIG. 4B is a view of a portion of a second member of the apparatus shownin FIG. 2.

FIG. 5A is a schematic representation of an exemplary tooth of theapparatus shown of FIG. 1.

FIG. 5B is a schematic representation of a configuration for teeth ofthe apparatus shown of FIG. 1.

FIG. 6A is a photograph of a highly magnified portion of an aperturedweb made by the process of the present invention.

FIG. 6B is a schematic representation of enlarged image of the film ofFIG. 6A.

FIG. 6C is a scanning electron microscope image of the A-A directioncross section of the film of FIG. 1A.

FIG. 7A is a plan view scanning electron microscope image of filmtopsheet of a commercially available sanitary napkin.

FIG. 7B is a plan view scanning electron microscope image of filmtopsheet of another commercially available sanitary napkin.

FIG. 7C is a plan view scanning electron microscope image of filmtopsheet of commercially available marketed sanitary napkin.

FIG. 8 is an AMF test photograph of a highly magnified portion of anapertured web of FIG. 6.

FIG. 9A is an AMF test photograph of a highly magnified portion of anapertured web from a commercial pad.

FIG. 9B is an AMF test photograph of a highly magnified portion of anapertured web from a commercial pad. (Web FIG. 3C)

FIG. 9C is an AMF test photograph of a highly magnified portion of anapertured web from a commercial pad. (Web FIG. 3D)

FIG. 10 is a chart showing softness scores for various aperture shapes.

The embodiments shown in the drawings are illustrative in nature and arenot intended to be limiting of the invention defined by the claims.Moreover, the features of the invention will be more fully apparent andunderstood in view of the detailed description.

DETAILED DESCRIPTION

The term “absorbent article” includes disposable articles such assanitary napkins, panty liners, tampons, interlabial devices, wounddressings, diapers, adult incontinence articles, wipes, and the like.Still further, the absorbent members produced by the methods andapparatuses disclosed herein can find utility in other webs such asscouring pads, dry-mop pads (such as SWIFFER® pads), and the like. Atleast some of such absorbent articles are intended for the absorption ofbody liquids, such as menses or blood, vaginal discharges, urine, andfeces. Wipes may be used to absorb body liquids, or may be used forother purposes, such as for cleaning surfaces. Various absorbentarticles described above will typically comprise a liquid pervioustopsheet, a liquid impervious backsheet joined to the topsheet, and anabsorbent core between the topsheet and backsheet.

The term “absorbent core”, as used herein, refers to the component ofthe absorbent article that is primarily responsible for storing liquids.As such, the absorbent core typically does not include the topsheet orbacksheet of the absorbent article.

The term “adjacent”, as used herein, with reference to features orregions, means near or close to, and which need not be in contact witheach other.

The term “aperture”, as used herein, refers to a hole. The apertures caneither be punched cleanly through the web so that the materialsurrounding the aperture lies in the same plane as the web prior to theformation of the aperture (a “two dimensional” aperture), or holesformed in which at least some of the material surrounding the opening ispushed out of the plane of the web. In the latter case, the aperturesmay resemble a protrusion or depression with an aperture therein, andmay be referred to herein as a “three dimensional” aperture, a subset ofapertures.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article, such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs.

The term “cross-machine direction” or “CD”, as used herein, refers tothe path that is perpendicular to the machine direction in the plane ofthe web.

The term “deformable material”, as used herein, is a material which iscapable of changing its shape or density in response to applied stressesor strains.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember, it is meant that the distal (or radially outwardmost) ends ofthe forming elements are distinct or unconnected in all directions,including in the machine and cross-machine directions (even though basesof the forming elements may be formed into the same surface of a roll,for example).

The term “forming elements”, as used herein, refers to any elements onthe surface of one member of a forming apparatus that are capable ofdeforming a web.

The term “layer” is used herein to refer to an absorbent member whoseprimary dimension is X-Y, i.e., along its length (or longitudinaldirection) and width (or transverse direction). It should be understoodthat the term “layer” is not necessarily limited to single layers orsheets of material. Thus the layer can comprise laminates orcombinations of several sheets or webs of the requisite type ofmaterials. Accordingly, the term “layer” includes the terms “layers” and“layered”.

The term “machine direction” or “MD” means the path that material, suchas a web, follows through a manufacturing process.

The term “macroscopic”, as used herein, refers to structural features orelements that are readily visible and distinctly discernible to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches (30 cm). Conversely, the term“microscopic” refers to such features that are not readily visible anddistinctly discernible under such conditions.

The term “mating elements”, as used herein, refers to any elements onthe surface of one member of a forming apparatus that are capable ofengaging the forming elements to deform a web.

The terms “mechanical deformation”, as used herein, refers to processesin which a mechanical force is exerted upon a material to formtwo-dimensional or three-dimensional structures on a web.

The term “surrounded”, as used herein, refers to both being completelyand continuously surrounded, and being discontinuously surrounded byother regions and/or apertures.

The present inventions are directed to methods and apparatuses forforming apertures in a web. Methods and apparatuses are disclosed thatare capable of forming new structures in webs that provide the webs withadditional properties. The methods and apparatuses can fabricate anaperture web having a three dimensional structure by forming macroapertures so that the web imparts improved fluid drainage as well as asoftness.

It should be understood that while the term “apertured web(s)” isutilized herein, the object is to create components, such as absorbentmembers (or non-absorbent components), for absorbent articles from suchapertured webs. In such cases, the apertured webs will be cut intoindividual components for absorbent articles. The apertured webs canalso be used in products other than absorbent articles including, butnot limited to packaging materials and trash bags.

Precursor Web

A precursor web that will be apertured can comprise any suitabledeformable material, such as a woven, nonwoven, polymeric film. Theprecursor web of the present invention can be a composite or a laminatecomprising a polymeric film, and optionally a nonwoven web, a wovenfabric, a paper web, a tissue web, or a knitted fabric.

The precursor web can be a polymeric film web. Polymeric film webs canbe deformable. Deformable, as used herein, describes a material which,when stretched beyond its elastic limit, will substantially retain itsnewly formed conformation. Such deformable materials may be chemicallyhomogeneous or heterogeneous, such as homopolymers and polymer blends,structurally homogeneous or heterogeneous, such as plain sheets orlaminates, or any combination of such materials.

Deformable polymeric film webs that can be used can have atransformation temperature range in which changes in the solid statemolecular structure of the material occur. Changes in the structure caninclude a change in crystalline structure and/or a change from solid tomolten state. As a consequence, above the transformation temperaturerange, certain physical properties of the material are substantiallyaltered. For a thermoplastic film, the transformation temperature rangeis the melt temperature range of the film, above which the film is in amolten state and loses substantially all previous thermo-mechanicalhistory.

Polymeric film webs can comprise thermoplastic polymers havingcharacteristic rheological properties which depend on their compositionand temperature. Below their glass transition temperature, suchthermoplastic polymers can be hard, stiff, and/or brittle. Below theglass transition temperature, the molecules are in rigid, fixedpositions. Above the glass transition temperature but below the melttemperature range, thermoplastic polymers exhibit viscoelasticity. Inthis temperature range, the thermoplastic material generally has acertain degree of crystallinity, and is generally flexible and to somedegree deformable under a force. The deformability of such athermoplastic is dependent on the rate of deformation, amount(dimensional quantity) of deformation, length of time it is deformed,and its temperature. In one embodiment, processes can be utilized toform materials comprising thermoplastic polymers, especiallythermoplastic film, which are within this viscoelastic temperaturerange.

Polymeric film webs can comprise a certain amount of ductility.Ductility, as used herein, is the amount of permanent, unrecoverable,plastic strain which occurs when a material is deformed, prior tofailure (rupture, breakage, or separation) of the material. Materialsthat can be used as described herein can have a minimum ductility of atleast about 10%, or at least about 50%, or at least about 100%, or atleast about 200%.

Polymeric film webs can include materials normally extruded or cast asfilms such as polyolefins, nylons, polyesters, and the like. Such filmscan be thermoplastic materials such as polyethylene, low densitypolyethylene, linear low density polyethylene, polypropylenes andcopolymers and blends containing substantial fractions of thesematerials. Such films can be treated with surface modifying agents toimpart hydrophilic or hydrophobic properties, such as imparting a lotuseffect. As noted below, polymeric film webs can be textured or otherwisealtered from a strictly flat, planar configuration.

The precursor web of the present invention can be a nonwoven web. Asused herein, the term “nonwoven web” refers to a web having a structureof individual fibers or threads which are interlaid, but not in arepeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven webs or fabrics havebeen formed from many processes, such as, for example, meltblowing,spunbonding, hydroentangling, airlaid, wetlaid, through-air-dried papermaking processes, and bonded carded web processes, including cardedthermal bonding. The nonwoven webs can comprise unbonded fibers,entangled fibers, tow fibers, or the like. Fibers can be extensibleand/or elastic, and may be pre-stretched for processing. Fibers can becontinuous, such as those produced by spunbonded methods, or cut tolength, such as those typically utilized in a carded process. Fibers canbe absorbent, and can include fibrous absorbent gelling materials.Fibers can be bicomponent, multiconstituent, shaped, crimped, or in anyother formulation or configuration known in the art for nonwoven websand fibers. The nonwoven webs comprising polymer fibers havingsufficient elongation properties to be formed into an apertured web. Ingeneral, the polymeric fibers can be bondable, either by chemical bond(e.g. by latex or adhesive bonding), pressure bonding, or thermalbonding. If thermal bonding techniques are used in the bonding processdescribed below, a certain percentage of thermoplastic material, such asthermoplastic powder or fibers can be used

The web of the present invention can be a composite or a laminate of twoor more precursor webs, and can comprise two or more nonwoven webs or acombination of polymer films, nonwoven webs, woven fabrics, paper webs,tissue webs, or knitted fabrics. In general, a web formed from alaminate precursor web could be comprised of apertures 6 whereinsidewalls of the apertures 6 comprise one or more of the precursor webmaterials.

The web can also optionally include colorants, such as pigment, lake,toner, dye, ink or other agent used to impart a color to a material, toimprove the visual appearance of an apertured web. Suitable pigmentsherein include inorganic pigments, pearlescent pigments, interferencepigments, and the like.

The precursor web can also optionally include colorants, such aspigment, lake, toner, dye, ink or other agent used to impart a color toa material, to improve the visual appearance of an apertured web.Suitable pigments herein include inorganic pigments, pearlescentpigments, interference pigments, and the like.

In one non-limiting embodiment, the precursor web comprises discreteextended elements formed therein, the discrete extended elementscomprising open proximal ends, open or closed distal ends, andsidewalls. The discrete extended elements can be aperture protrusions,non-apertured protrusions or fibrils to provide texture that providesfor a tactile impression of softness. The discrete extended elements mayhave a diameter of less than about 500 microns; the discrete extendedelements have an aspect ratio of at least about 0.2; and/or theprecursor web comprises at least about 95 discrete extended elements persquare centimeter.

Softness is beneficial when webs are used as topsheets in disposableabsorbent articles. The method according to the present invention iseffective in preserving the micro texture discrete extended elements 2without heat-induced damages, particularly when the apertures 6 are madeon the disposable absorbent article production line. In this manner, asoft, compliant topsheet for a disposable absorbent article can beprepared when the apertured web is used with the second surface 14having the discrete extended elements 2 as the body-facing surface ofthe article.

Methods and Apparatuses for Aperture Formation

The present invention will be described with respect to a method andapparatus used for making a web comprising microscopic textures andquadrilateral macroscopic apertures to provide enhanced fluid drainageand softness to the wears' skin.

The mechanical aperture formation process of the present invention canbe carried out on any suitable apparatus that may comprise any suitabletype(s) of forming structure. Suitable types of forming structuresinclude, but are not limited to: a pair of rolls that define a niptherebetween, pairs of plates, belts, etc. Using an apparatus with rollscan be beneficial in the case of continuous processes, particularlythose in which the speed of the process is of interest. Although theapparatuses will be described herein for convenience primarily in termsof rolls, it should be understood that the description will beapplicable to forming structures that have any other suitableconfigurations.

The rolls used in the apparatuses and methods described herein aretypically generally cylindrical. The term “generally cylindrical”, asused herein, encompasses rolls that are not only perfectly cylindrical,but also cylindrical rolls that may have elements on their surface. Theterm “generally cylindrical” also includes rolls that may have astep-down in diameter, such as on the surface of the roll near the endsof the roll. The rolls are also typically rigid (that is, substantiallynon-deformable). The term “substantially non-deformable”, as usedherein, refers to rolls having surfaces (and any elements thereon) thattypically do not deform or compress under the conditions used incarrying out the processes described herein. The rolls can be made fromany suitable materials including, but not limited to steel, aluminum orrigid plastic. The steel may be made of corrosion resistant and wearresistant steel, such as stainless steel. The rolls may or may not beheated. If heated, consideration of thermal expansion effects must beaccommodated according to well known practices to one skilled in the artof thermo-mechanical processes.

The rolls may have any suitable type of elements on their surface (orsurface configuration) to form quadrilateral macroscopic apertures on aweb. The rolls may have any suitable type of elements on their surface(or surface configuration). The surface of the individual rolls may beprovided with forming elements comprising: male elements such asdiscrete projections and teeth having a shape to form the quadrilateralapertures and being arranged in a staggered pattern; female elementssuch as recesses such as discrete voids in the surface of the rolls; orany suitable combination thereof. The female elements may have a bottomsurface (which may be referred to as depressions, or cavities), or theymay be in the form of apertures (through holes in the surface of therolls).

The forming elements may have any suitable configuration. One type ofmale elements useful in the present invention are teeth having a base ina generally polygonal shape such as octagonal, hexagonal andquadrilateral shape, and having a cross-sectional length and across-sectional width. “Polygonal” herein intends to include polygonalwith rounded corners. The teeth have any suitable aspect ratio of itscross-sectional length to its cross-sectional width to formquadrilateral apertures on a web. The cross-sectional length may belonger than the cross-sectional width, but it does not include the casethat cross-sectional length and the cross-sectional width are in thesame length. In one embodiment, the teeth have a generally hexagonalshape base. In another embodiment, the teeth have a generallyquadrilateral shape base.

The male elements can have tips that are flat, rounded or sharp. Incertain embodiments, the shapes of the female elements may differ fromthe shapes of any mating male elements.

A method according to the present invention can produce an apertured webfrom a precursor web having a plurality of discrete extended elementsextended outwardly from a first surface the precursor web by forming aplurality of macro apertures on the precursor web continuously.

One process of the present invention is shown schematically in FIG. 1.Precursor web 20 is moved in the machine direction to forming apparatus100 where apertures 6 are formed producing apertured web 1. Precursorweb 20 can be supplied from a supply roll 152 (or supply rolls, asneeded for multiple web laminates) or any other supply means, such asfestooned webs, as is known in the art. In one embodiment, precursor web20 can be supplied directly from a web making apparatus, such as apolymer film extruder. Subsequent to formation, apertured web 1 can betaken up on a supply roll 160 for storage and further processing as acomponent in other products. Alternatively, apertured web 1 can beconveyed directly to further post processing, including a convertingoperation for incorporation into a finished product, such as adisposable absorbent product.

Referring to FIG. 1, a method according to the present invention canproduce an aperture web from a three dimensional precursor web where aplurality of discrete extended elements are formed on the precursor web20 by forming macro apertures on the precursor web. First surface 12corresponds to a first side of precursor web 20, as well as a first sideof apertured web 1. Second surface 14 corresponds to a second side ofprecursor web 20, as well as a second side of apertured web 1. Ingeneral, the term “side” is used herein in the common usage of the termto describe the two major surfaces of generally two-dimensional webs,such as films. Of course, in a composite or laminate structure, thefirst surface 12 of the apertured web 1 is the first side of one of theoutermost layers or plies, and the second surface 14 is the second sideof the other outermost layer or ply.

In one embodiment precursor web 20 can be a polymeric film web suitablefor use as a topsheet in a disposable absorbent product, as is known inthe art.

Precursor web 20 can be preheated by means known in the art, such as byradiant heating, forced air heating, convection heating, or by heatingover oil-heated rollers. Precursor web 20 can be pre-printed withindicia, designs, logos, or other visible or invisible print patterns.For example, designs and colors can be printed by means known in theart, such as by ink-jet printing, gravure printing, flexographicprinting, or offset printing, to change the color of at least portionsof precursor web 20. In addition to printing, precursor web 20 can betreated with coatings, such as with surfactants, lotions, adhesives, andthe like. Treating precursor web 20 can be achieved by means known inthe art such as by spraying, slot coating, extruding, or otherwiseapplying coatings to one or both surfaces.

Supply roll 152 rotates in the direction indicated by the arrow in FIG.1 as precursor web 20 is moved in the machine direction by means knownin the art, including over or around any of various idler rollers,tension-control rollers, and the like (all of which are not shown) tothe nip 116 formed by a pair of counter-rotating, intermeshing rolls 102and 104. The pair of intermeshing rolls 102 and 104 operate to formapertures in web 20 forming apertured web 1. Intermeshing rolls 102 and104 are more clearly shown in FIG. 2.

Referring to FIGS. 1 and 2, there is shown in more detail the portion offorming apparatus 100 for making apertures in apertured web 1. Thisportion of apparatus 100 is shown as forming apparatus 100 in FIG. 2,and comprises a pair of intermeshing rolls 102 and 104 rotating inopposite directions. Forming apparatus 100 can be designed such thatprecursor web 20 remains on roll 104 through a certain angle ofrotation. While FIG. 1 shows precursor web 20 going straight into andaperture web 1 coming straight out of nip 116, precursor web 20 orapertured web 1 can be partially wrapped on either of rolls 102 or 104through a predetermined angle of rotation prior to (for precursor web20) or after (for apertured web 1) nip 116. For example, after exitingnip 116, apertured web 1 can be directed to be wrapped on roll 104through a predetermined angle of rotation such that the apertures remainresting over, and “fitted” onto, teeth 110 of roll 104.

Rollers 102 and 104 can be made of steel, aluminum, an alloy metal,rigid plastic. In one embodiment, the rollers can be made of stainlesssteel. In general, rollers 102 and 104 can be made of corrosionresistant and wear resistant metal.

Roll 102 can comprise one or more discrete recesses or voids 108 intowhich one or more of teeth 110 of roll 104 mesh. The recess 108 may havethe same shape as a base of the teeth 110 and slightly larger dimensionson all edges and side than the base of the teeth 110. The depth of therecess may be deeper than a height of the teeth 110. The recess may ormay not be tapered. In the case, the spacing of apertures formed on aweb is limited by the spacing of the recesses on roll 102. Thus, itwould not be possible to form apertures in the web that have a smallercenter-to-center spacing than the center-to-center spacing of therecesses on roll 102.

Roll 104 comprises a plurality of rows of circumferentially-spaced teeth110 that extend in spaced relationship about at least a portion of roll104. Teeth 110 are arranged in a staggered pattern. Teeth 110 extendradially outwardly from the surface of the roll 102 to engage recesses108 of roll 102. The engagement is shown in greater detail in the crosssectional representation of FIG. 3, discussed below.

Teeth 110 can be joined to roller 104. The term “joined to” encompassesconfigurations in which an element is secured to another element atselected locations, as well as configurations in which an element iscompletely secured to another element across the entire surface of oneof the elements. The term “joined to” includes any known manner in whichelements can be secured including, but not limited to mechanicalentanglement. Teeth can be attached to, such as by welding, compressionfit, or otherwise joined. However, “joined to” also includes integralattachment, as is the case for teeth machined by removing excessmaterial from roller 104. The location at which teeth 110 are joined toroller 104 is the base. At any cross-sectional location parallel to thebase each tooth can have a non-round cross-sectional area. In analternate embodiment the teeth may comprise pins that are diamond,rectangular or square depending on the corresponding aperture shapedesired.

FIG. 3 shows in cross section a portion of the intermeshing rolls 102and 104 including representative teeth 110. As shown, teeth 110 have atooth height TH, depth of engagement E, and gap clearance C. A toothheight TH may range from about 0.5 mm to about 10 mm Depth of engagementE is a measure of the level of engaging rolls 102 and 104 and ismeasured from a top surface of the roll 102 to tip 102 of tooth 110 ofthe roll 104. Gap clearance C is a distance between a top surface of theroll 102 and a bottom surface of the roll 104 when rolls 102 and 104 arein maximum engagement. Gap clearance is preferably wide enough toprevent discrete extended elements formed in a precursor web fromheat-induced damages from for example a macro aperture forming step, andthus the discrete extended elements remain substantially intact duringmacro aperture formation process and softness of the web is notcompromised or even enhanced. Heat-induced damages include permanentdeformation of at least part the discrete extended elements, hardeningpart of the discrete extended elements as a result of exposure to theheat. Gap clearance preventing discrete extended elements fromheat-induced damages can be determined in consideration of precursor webproperty, precursor web thickness, height of microtextures, macroaperture formation process operation conditions such as roll temperatureand production speed. In one embodiment, gap clearance is greater thanor equal to the average height of microtextures such as the discreteextended elements formed on the precursor web. In another embodiment,clearance may be no less than about 1.5 mm, or less than about 1.6 mm.

Without wishing to be bound by any particular theory, it is believedthat undamaged discrete extended elements on a surface of a web canprovide softness to the skin when the web is intended to form at least aportion of the wearer-facing surface of an absorbent article and thesurface of the web is in at least partial contact with the skin of awearer.

The size and shape of the tooth tip 112 may be specified via the tipradius TR. The depth of engagement E, tooth height TH, and clearance Ccan be varied as desired depending on the properties of precursor web 20and the desired characteristics of apertured web 1. It is alsocontemplated that the size, shape, orientation and spacing of the teeth110 can be varied about the circumference and width of roll 104 toprovide for varied apertured web 1 properties and characteristics.

Both or either of rolls 102 and 104 can be heated by means known in theart such as by incorporating hot oil filled rollers orelectrically-heated rollers. Alternatively, both or either of the rollsmay be heated by surface convection or by surface radiation.

Additionally, substances such as lotions, ink, surfactants, and the likecan be sprayed, coated, slot coated, extruded, or otherwise applied toapertured web 1 before or after entering nip 116. Any processes known inthe art for such application of treatments can be utilized.

FIG. 4A shows a portion of one embodiment of a roller 104 having aplurality of teeth 110 useful for making an apertured web 1. FIG. 4Bshows a portion of one embodiment of a roller 102 having a plurality ofrecesses 108 arranged in a staggered pattern useful for making anapertured web 1.

A perspective view of an exemplary configuration for teeth 100 is shownin FIG. 5A. As shown in FIG. 5A, each tooth 110 has a base 111, a toothtip 112, edges 113, and sides 114. Teeth 110 can have a base in agenerally polygonal shape. As opposed to round, pin-like shapes that aregenerally round in cross section, teeth 110 can be elongated in onedimension or two dimensions, having generally non-round, elongatedcross-sectional configurations. For example, at their base 111, thecross section of teeth 110 can have a tooth cross-sectional length TLand a tooth cross-sectional width TW exhibiting a tooth aspect ratio ARof TL/TW of not greater 3.3, or not greater than 2.5, or not greaterthan 2, or not greater than 1.9. In one embodiment, each of the teethhas a quadrilateral shape base. The teeth 110 are tapered from a base toa tip in a way that a degree of taper is not constant along the heightof the teeth. The tooth 110 may comprise a proximal part 120 joined to amember of a forming apparatus, and a distal part 130 directly adjacentto the proximal part and tapering to a tooth tip 112. The tooth 110 maycomprise a proximal part, a distal part, and a middle part between theproximal part 120 and the distal part 130. The proximal part and thedistal part may have different degree of taper from each other. In oneembodiment, the distal part 130 has a higher degree of taper than theproximal part 120. In another embodiment, at least one of the proximalpart 120 and the distal part 130 has a constant degree of taper. Theproximal part is generally a fructum shape tapering from a generallypolygonal-shape base such as a quadrilateral-shape and a hexagonal-shapeto a point. As shown in FIG. 5A, a proximal part 120 can have four sides114, each side being generally (isosceles) rectangular. The vertex oftwo sides makes up an edge. The vertices of edges 113 can be relativelysharp, or can be machined to have a rounded radius of curvature. Asshown in FIG. 5A, a distal part 130 can have a generally pyramid shapehaving at least four sides 114′, each side being substantiallytriangular and tapering from the bottom of the distal part to a tip ofthe tooth. The vertex of two sides of the distal part 130 makes up anedge. The vertices of edges 113′ can be relatively sharp, or can bemachined to have a rounded radius of curvature. The tooth tip 112 can begenerally pointed, blunt pointed, or otherwise shaped so as to stretchand/or puncture the precursor web 20. The outermost tips 112 of theteeth have sides that may be rounded to avoid cuts or tears in theprecursor material.

In another embodiment, other tooth shapes can be utilized to makeapertures. For example, the generally pyramidal shape of distal part 130shown in FIG. 5A can be truncated so as to remove the pointedness oftips 112 and a flattened region is produced at the distal end of tooth110. The flattened region can also be elongated, that is, having alength dimension greater than a width dimension and an aspect ratio ARcorresponding to the aspect ratio of tooth 110. In one embodiment, aflattened region can transition to sides 114 at generally sharpvertices, or the transition can be at a radius of curvature, providingfor a smooth, rounded, flattened tooth tip. Without being bound bytheory, it is believed that having relatively sharp tips on teeth 110permits the teeth 110 to punch through precursor web 20 “cleanly”, thatis, locally and distinctly, so that the resulting apertured web 1 can bedescribed as being predominantly “apertured” rather than predominantly“embossed”. In one embodiment, puncture of precursor web 20 is cleanwith little deformation of web 20, such that the resulting web is asubstantially two-dimensional perforated web.

Another exemplary configuration for teeth 100 is shown in FIG. 5B. Theteeth 110 having a cross sectional length TL and a cross sectional widthTW are arranged in a staggered pattern to have a tooth-to-tooth spacingP_(L) between two adjacent teeth along the cross-sectional lengthdimension, a tooth-to-tooth spacing P_(W) between two adjacent teethalong the cross-sectional width dimension, and a tooth-to-tooth spacingPs between two adjacent teeth along a line that is not parallel eitherto the cross-sectional length dimension or to the cross-sectional widthdimension. The teeth 110 may have different lengths of tooth-to-toothspacing P_(S), P_(S1) and P_(S2), depending on teeth configuration. Byreferring to FIGS. 5A and 5B, in teeth FIG. 5B, the base 111 has ahexagonal shape by slightly cutting out two opposite edges 113 of theproximal part. Edges 113′ of the distal part 130 corresponding to thetwo opposite edges 113 of the proximal part also cut out.

In one embodiment, a tooth-to-tooth spacing Ps is not greater than orequal to about 1.9 mm, or not greater than 1.7 mm, or not greater thanabout 1.5 mm. In another embodiment, at least one of the tooth-to-toothspacings P_(L) and P_(W) is greater than about 1.9 mm, or greater thanabout 1.7 mm, or greater than about 1.5 mm.

Of course, tooth-to-tooth spacings P_(L), P_(w) and/or Ps, tooth crosssectional length TL, and tooth cross sectional width TW can each bevaried independently of each other to achieve a desired size, spacing,and area density of apertures 6.

The precursor web 20 comprises a plurality of discrete extendedelements. In one non-limiting embodiment, the discrete extended elementshave a diameter of less than about 500 microns; the discrete extendedelements have an aspect ratio of at least about 0.2; and/or the webcomprises at least about 95 discrete extended elements per squarecentimeter. The discrete extended elements can also be apertureprotrusions, non-apertured protrusions or fibrils to provide texturethat provides for a tactile impression of softness.

Another process of the present invention comprises providing a precursorweb having a first surface and a second surface opposite to the firstsurface, forming a plurality of discrete extended elements extendingoutwardly from the first surface of the precursor web, and continuouslyforming a plurality of macro apertures extended outwardly from thesecond surface of the precursor web according to the method disclosedabove.

Patent publications disclosing such a plurality of discrete extendedelements include WO 01/76842; WO 10/104996; WO 10/105122; WO 10/105124and US20120277701A1.

The web with discrete extended elements can be provided using anyprocess known in the art. Providing the web with discrete extendedelements will provide the exterior surfaces of the web with a softer,more cloth-like texture, provide the web with a more cloth-likeappearance, and increase the overall caliper of the web. Examples ofdiscrete extended elements processes include but are not limited to thefollowing: hydroforming, vacuum forming, mechanical deformation,flocking, ultrasonics, delamination of viscous melts from poroussurfaces, printed hair, brushing, and any combination thereof.

In one embodiment, three dimensional surface structures comprisingdiscrete extended elements are formed by applying a high pressure fluidjet comprised of water or the like against one surface of the formed webply, preferably while applying a vacuum adjacent the opposite surface ofthe formed web ply. In general, the formed web ply is supported on onelayer of a forming structure having opposed layers. The formingstructure is provided with a multiplicity of apertures there throughwhich place the opposed layers in fluid communication with one another.Such methods of aperturing are known as “hydroformation” and aredescribed in greater detail in U.S. Pat. Nos. 4,609,518; 4,629,643;4,637,819; 4,681,793; 4,695,422; 4,778,644; 4,839,216; and 4,846,821.

Vacuum formation is disclosed in U.S. Pat. No. 4,463,045.

Examples of mechanical deformation is disclosed in U.S. Pat. Nos.4,798,604, 4,780,352, 3,566,726, 4,634,440, WO 97/40793, and EuropeanPatent 525,676.

Examples of flocking are disclosed in WO 98/42289, WO 98/36721, andEuropean Patent 861,646.

Examples of ultrasonics are disclosed in U.S. Pat. No. 5,269,981.

Examples of delamination of viscous melts are disclosed in U.S. Pat. No.3,967,623, and WO 99/06623.

Examples of printed hair are disclosed in U.S. Pat. No. 5,670,110.

Examples of brushing are disclosed in WO 99/06623.

Apertured Web

Referring to FIGS. 6A and 6B, the apertured web 1 produced by a methodaccording to the present invention comprises a plurality of discreteextended elements 2 (not indicated in FIG. 6B) extended outwardly from afirst surface 12 of the web 1, and a plurality of spaced apartquadrilateral macro apertures 6.

The macro apertures may be planar and two dimensional or threedimensional. “Planar” and “two dimensional” is meant simply that the webis flat relative to apertured web 1 that has distinct, out-of-plane,Z-direction three-dimensionality imparted due to the formation ofapertures 6 with sidewalls. “Planar” and “two-dimensional” are not meantto imply any particular flatness, smoothness or dimensionality. In oneembodiment, the web according to the present invention comprises aplurality of three dimensional macro apertures.

As shown in FIG. 6A and FIG. 6C, the web of the present inventioncomprises macro apertures extended toward the second surface, the macroapertures having a major axis dimension and a minor axis dimension andbeing arranged in a staggered pattern. Apertures 6 extend in a directionaway from second surface 14 of web 1 while the discrete extendedelements 2 extend away from first surface 12 of web 1, so that theapertures 6 and the discrete extended elements 2 are formed in theopposite direction. The macro apertures are discrete, and substantiallyquadrilateral including rectangular, square, and lozenge shape.“Quadrilateral” herein intends to include quadrilateral with roundedcorners. Surprisingly, the inventors found that quadrilateral shapeapertures on a web provide enhanced softness feels by increasing acottony feel and reducing a plastic feel and an abrasive feel asdescribed later.

The macro apertures may have a ratio of a major axis dimension to minoraxis dimension of not greater than 3.3, or not greater than 2.5, or notgreater than 2. In another embodiment, the major axis of the macroapertures is substantially parallel to the MD of the web 1. In anotherembodiment, the major axis of the macro apertures is substantiallyparallel to the CD of web 1. In another embodiment, the major axis ofthe macro apertures is oriented at an angle relative to the MD. Despitethe terms of ‘major” and “minor” axes, it is intended that a major axisand a minor axis can have an identical length.

The web produced by a method according to the present invention hasimproved softness. As shown in FIGS. 6A and 6C, a plan view scanningelectron microscope image of a film according to the present inventionand a cross-section view thereof, respectively, the web prepared by amethod according to the present invention has substantially intactdiscrete extended elements 2 without substantial heat-induced damages.Without wishing to be bound by any particular theory, it is believedthat undamaged discrete extended elements on a surface of a web canprovide softness to the skin when the web is intended to form at least aportion of the wearer-facing surface of an absorbent article and thesurface of the web is in at least partial contact with the skin of awearer. FIGS. 7A-7C are plan view scanning electron microscope images offilm topsheets from commercial sanitary pads (FIG. 7A: Kotex U, KimberlyClark, Singapore; FIG. 7B: Lilian, Kleannara Co. Ltd, Korea; and FIG.7C: 7 Space Teens, Hengan Industrial Co. Ltd, China) showing circular oroval shape apertures and significantly damaged micro structures.

In addition, the web prepared by a method according to the presentinvention shows improved cottony feel, and reduced plastic feel andabrasive feel all of which contribute overall softness of the web. Forcottony feel, the higher is the better. For plastic feel and abrasivefeel, the lower is the better. As shown in FIG. 10, webs havingquadrilateral apertures, diamonds and square macro geometries, showedbetter scores in cottony feel, and reduced plastic feel and abrasivefeel, and provide the highest softness values.

Further, the web prepared by a method according to the present inventionexhibits improved fluid drainage as seen FIG. 8 and FIGS. 9A-9C, planview scanning electron microscope images showing results of FluidDrainage Test (FIG. 8: a pad having a topsheet from a web produced by amethod according to the present invention; FIG. 9A: Kotex U, KimberlyClark, Singapore; FIG. 9B: Lilian, Kleannara Co. Ltd, Korea, and FIG.9C: 7 Space Teens, Hengan Industrial Co. Ltd, China). The topsheet ofFIGS. 9A-9C have circular or oval shape macro apertures.

The plan view area of the individual macro aperture, in some embodimentsof the web, be greater than or equal to about 0.5 mm², 1 mm², 5 mm², 10mm², or 15 mm², or lie in any range between the macro apertures. Thenumber of apertures 6 per unit area of apertured web 1, i.e., the areadensity of apertures 6, can be varied from about 5-60 apertures persquare centimeter. In one embodiment, the web 1 comprises macroapertures with a macro aperture density of from about 10 to about 50, orfrom about 20 to about 40 macro aperture/cm² web. There can be at least20 apertures 6 per square centimeter, depending on the end use. Ingeneral, the area density need not be uniform across the entire area ofapertured web 1, but apertures 6 can be only in certain regions ofapertured web 1, such as in regions having predetermined shapes, such aslines, stripes, bands, circles, and the like. In one embodiment, whereapertured web 1 is used as a topsheet for a sanitary napkin, forexample, apertures 6 can be only in the region corresponding to thecentral part of the pad where fluid entry occurs.

Referring to FIG. 1, as precursor web 20 goes through the nip 116, theteeth 110 of roll 104 engages recesses 108 of roll 102 andsimultaneously urge material out of the plane of precursor web 20 toform permanent volcano-like shape apertures 6. In effect, teeth 110“push” or “punch” through precursor web 20. As the tip of teeth 110 pushthrough precursor web 20, the web material is urged by the teeth 110 outof the plane of precursor web 20 and is stretched and/or plasticallydeformed in the Z-direction, resulting in formation of apertures 6. Theamount of ductility and other material properties of the precursor web,such as the glass transition temperature and crystallinity determine howmuch relatively permanent three-dimensional deformation the aperturedweb 1 retains.

It is also contemplated that the size, shape and spacing of the teeth110 can be varied about the circumference and width of roll 104 toprovide for varied apertured web 1 properties and characteristics. Thenumber, spacing, and size of apertures 6 can be varied by changing theshape, number, spacing, orientation and size of teeth 110 and makingcorresponding dimensional changes as necessary to roll 104 and/or roll102. This variation, together with the variation possible in precursorwebs 20 and the variation in processing, such as line speeds, rolltemperature, and other post processing variations, permits many variedapertured webs 1 to be made for many purposes.

Referring to FIGS. 6A and 6B, the apertured web 1 produced by a methodaccording to the present invention may further comprises a plurality offirst regions 8, and a plurality of second regions 10.

Each of the first regions 8 is surrounded by four distinctive secondregions 10. The four distinctive second regions 10 surrounding the eachof the first regions 8 are connected by two adjacent macro apertures 6located along a first direction and another two adjacent macro apertures6 located long a second direction which is orthogonal to the firstdirection. Each of the second regions 10 is surrounded by two adjacentfirst regions 8, and two adjacent macro apertures 6 located either alonga third direction or along a fourth direction either of which is notparallel to the first direction and the second direction.

A center-to-center distance of the two adjacent macro apertures in thethird direction and/or a center-to-center distance of the two adjacentmacro apertures in the fourth direction are shorter than acenter-to-center distance of the two adjacent macro apertures in thefirst direction and/or a center-to-center distance of the two adjacentmacro apertures in the second direction. In one embodiment, acenter-to-center distance of the two adjacent macro apertures in thethird direction and a center-to-center distance of the two adjacentmacro apertures in the fourth direction are shorter than acenter-to-center distance of the two adjacent macro apertures in thefirst direction and a center-to-center distance of the two adjacentmacro apertures in the second direction. A center-to-center distance oftwo adjacent apertures is a measure between centers of two adjacentapertures. A point where major axis and a minor axis of an aperturecross each other may be determined as a center of the aperture.

As seen FIG. 8 referring to FIG. 6A, the second regions 10 have betterfluid drainage, for example measured according to Fluid Drainage Testdescribed below. Without wishing to be bound by any particular theory,it is believed that the short top plane length of the second regions iseffective to drain fluid and prevent the fluid from being trapped invalleys between micro structures such as discrete extended elements.

The web 1 may be a single layer web made from a single layer precursorweb, a laminate or composite precursor web having two or more layers orplies. In general, a web 1 formed from a laminate precursor web could becomprised of apertures 6 wherein sidewalls of the apertures 6 compriseone or more of the precursor web materials.

It should be understood that while the term “apertured web” is utilizedherein, the object is to create components for absorbent articles fromsuch apertured web. In such cases, the apertured web will be cut intoindividual components for absorbent articles. The apertured web can alsobe used in products other than absorbent articles.

Test Methods

Fluid Drainage Test

Artificial Menstrual Fluid Simulant (“AMFS”) Preparation

The Artificial Menstrual Fluid Simulant (referred to herein as “AMFS”)used in this testing is composed of 70% defibrinated sheep's blood and30% of a solution comprised of melted gelatin, anionic polyacrylamideflocculant, and phosphate-buffered saline solution. Such an AMFS isdescribed in more detail in U.S. Pat. No. 7,659,372.

The melted gelatin is prepared by combining 7 grams of edible-grade,unflavored gelatin with 85 grams of sterile distilled water. Thecomponents are heated and stirred until dissolution. The solution isallowed to solidify in a 4° C. refrigerator overnight. Thephosphate-buffered saline solution is prepared by combining 22 grams ofa solution containing 0.138% hydrous monobasic sodium phosphate and0.85% sodium chloride with 70 grams of a solution containing 0.14% ofanhydrous dibasic sodium phosphate and 0.85% sodium chloride. Theanionic polyacrylamide flocculant, available from Kemira as Superfloc™A-150, is prepared by combining 1 gram of the flocculant beads with a 1%sodium chloride solution in sterile distilled water. The solution is setat room temperature for one week.

To make 100 ml of AMFS, 7 grams of solidified gelatin is added to 21.5grams phosphate-buffered saline solution and heated on a hotplate at 35°C. until visually melted. This solution is allowed to cool to 25° C.Then 1.5 grams of anionic polyacrylamide flocculant is added, followedby 70 grams of defibrinated sheep's blood available from ClevelandScientific. The resulting AMFS is inverted ten times to ensure componentmixing and is then placed in a 4° C. refrigerator overnight.

The AMFS viscosity is checked for testing suitability using a TAInstruments AR 1500 or AR 2000 rotational rheometer. After allowing theAMFS batch to warm to 25° C., it is tested at a 25° C. instrumenttemperature using a steel, 40 mm, 0° plate with a gap 500-1000 micronsthat ramps shear rate from 0.5 to 30 1/s. Linear regression is appliedto the resulting shear curve and the viscosity is calculated for a shearrate of 20 1/s. An AMFS viscosity of 17-23 centipoise at 20 1/s isconsidered acceptable for use in the test methods herein.

Fluid Drainage

a) An absorbent article to be test is unfolded, and removed from allrelease papers/films/tapes. The absorbent article is flattened and fixedon an A4 paper by using adhesives on the back side of a backsheet of theabsorbent article.

b) The absorbent article is placed under an optical microscope such asSZX 12, Olympus optionally equipped with a digital camera. A focallength and a light intensity are adjusted under a total magnification16×.

c) 2 ml of AMFS prepared according to Artificial menstrual FluidSimulant (“AMFS”) Preparation is applied to a focal point of theabsorbent article for about 5 seconds using a pipette. AMFS drainage isrecorded by a video connected to the microscope for 3 minutes from theAMFS application.

d) A photo of the absorbent article after 3 seconds from the moment AMSFdrainage progress is not observed any more is screened from the recordedvideo.

EXAMPLE Example 1 Fluid Drainage Test

A non-limiting example of web film according to the present inventionwas produced by running micro apertured, a 70 mesh poly ethylene film,against a forming apparatus of FIGS. 1 and 2 having teeth of FIG. 5B.The teeth are arranged in a staggered pattern, and oriented to having amajor axis in a MD and a minor axis in a CD. The film was activated at atemperature of 60-90° C. FIG. 6 is a highly magnified portion of theobtained web film obtained by SEM (TM3000, Hitachi, Japan). A sanitarypad was prepared using the film obtained as a tophseet. Fluid drainageof a pad prepared in Example 1 and commercially available sanitary padswere tested according to Fluid Drainage Test described in TEST METHODSsection. Results are shown in FIG. 8 and FIGS. 9A-9C. As shown, the padprepared in example 1 exhibits excellent fluid drainage.

Example 2 Softness Test

A non-limiting example of web film according to the present inventionwas produced by running micro apertured, a 70 mesh poly ethylene film,against a forming apparatus of FIGS. 1 and 2 having teeth of FIG. 5B.The teeth are arranged in a staggered pattern, and oriented to having amajor axis in a MD and a minor axis in a CD. The film was activated at atemperature of 60-90° C. A film (“Diamond” sample) having diamond shapeapertures in a density of 29 apertures/cm²web was prepared. Web filmshaving various aperture geometries were produced by the same process asDiamond sample from the same precursor web.

Rectangle: rectangle shape apertures with dimensions of 1.05 mm×0.78 mm25 apertures/cm²web

Circle 2: circle shape apertures with a diameter of 2.0 mm, 18apertures/cm²web

Circle 2.5: a circle shape apertures with a diameter of 2.5 mm, 12apertures/cm²web

Hexagon: hexagon shape apertures with dimensions of a side of 1.15 mm, awidth of 1.50 mm and a height of 2.5 mm, 16 apertures/cm²web

Sanitary pads were prepared using each of the films obtained as atophseet, an identical absorbent core a backsheet.

With 12 expert panels, cottony feel (degree to which the product feelslike brushed cotton, 0: not at all cottony, 8: extremely cottony),plastic feel (degree of plastic feel, 0: Not at all plastic, 8:extremely plastic), abrasive feel (roughness, prickles, sharpness, 0:not Abrasive, 8: extremely abrasive) of each sample were measured in 0-8scales. Results are shown in FIG. 10.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “90°” is intended to mean“about 90°”.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making an apertured web, the methodcomprising the steps of: a) providing a precursor web having a firstsurface and a second surface opposite to the first surface, comprising aplurality of discrete extended elements on the first surface, thediscrete extended elements comprising open proximal ends, open or closeddistal ends, and sidewalls, b) providing a forming apparatus for macroapertures comprising a first member and a second member, wherein thefirst member comprises male elements on its surface and the secondmember comprises discontinuous female elements on its surface, and c)moving the precursor web through the first and second members so thatmacro apertures are formed in the precursor web as the male elements andthe female elements are engaged, wherein the macro apertures have aquadrilateral shape, wherein the male elements comprising teeth having ashape to form the macro apertures having a quadrilateral shape on theprecursor web, and being arranged in a staggered pattern.
 2. The methodaccording to claim 1, wherein the each of the teeth comprises a proximalpart joined to the first member on the surface of the first member, anda distal part directly adjacent to the proximal part and tapering to atip of the each of the teeth, the proximal part and the distal parthaving different degree of taper from each other.
 3. The methodaccording to claim 2, wherein each of the teeth further comprises amiddle part between the proximal part and the distal part, the middlepart having a degree of taper different from the proximal part.
 4. Themethod according to claim 1, wherein the each of the teeth has a basehaving a polygonal shape.
 5. The method according to claim 4, whereinthe each of the teeth has a base having a shape selected from the groupconsisting of a quadrilateral shape, a hexagonal shape, an octagonalshape and combinations thereof.
 6. The method according to claim 1,wherein the precursor web comprises the discrete extended elementsselected from discrete extended elements having a diameter of less thanabout 500 microns, discrete extended elements having an aspect ratio ofat least about 0.2, at least about 95 discrete extended elements persquare centimeter, and mixtures thereof.
 7. The method according toclaim 1, wherein the teeth has a base having a ratio of across-sectional length to a cross-sectional width not greater than about3.3.
 8. The method according to claim 1, wherein the first membercomprises male elements with a male element density of from about 5 toabout 60 male elements/cm².
 9. The method according to claim 1, whereinat least one of the first and the second members is a generallycylindrical roll.
 10. The method according to claim 1, wherein the teethare arranged so that the cross-sectional length dimension is parallel toa machine direction or a cross direction.
 11. The method according toclaim 1, wherein the teeth are arranged so that the cross-sectionallength dimension is not parallel either to a machine direction or to across direction.
 12. The method according to claim 1, wherein the teethhave a tooth-to-tooth spacing between two adjacent teeth located along aline that is not parallel either to the cross-sectional length dimensionor to the cross-sectional width dimension not greater than about 1.9 mm.13. The method according to claim 1, wherein the precursor web is apolymeric film or a laminate having a polymeric film layer.
 14. Themethod according to claim 1, wherein at least one of the first memberand the second member is heated.
 15. The method according to claim 14,wherein the first member and the second member have a clearance betweena top surface of the second member and a bottom surface of the firstmember when the first member and the second member are in maximumengagement so that the discrete extended elements are substantiallyintact from heat-induced damages after the step c).
 16. The methodaccording to claim 15, wherein the clearance is no less than about 1.5mm.
 17. The method according to claim 1, wherein the discrete extendedelements are formed by a vacuum formation process.
 18. A method formaking an apertured web, the method comprising the steps of: a)providing a precursor web having a first surface and a second surfaceopposite to the first surface, b) providing a first process selectedfrom the group consisting of hydroforming, vacuum forming, mechanicaldeformation, high static pressure forming, and combinations thereof, c)providing a second process using a forming apparatus, the formingapparatus comprising a first member and a second member, wherein thefirst member comprises male elements on its surface and the secondmember comprises female elements on its surface, d) forming a pluralityof discrete extended elements on the first surface of the precursor webby the first process, e) forming macro apertures on the precursor web bythe second process, moving the precursor web through the first andsecond members so that macro apertures are formed in the precursor webas the male elements and the female elements are engaged, wherein themacro apertures have a quadrilateral shape, and wherein the maleelements comprising teeth having a shape to form the macro apertureshaving a quadrilateral shape on the precursor web, and being arranged ina staggered pattern.
 19. The method according to claim 18, wherein thefirst process is vacuum forming process.
 20. The method according toclaim 18, wherein each of the teeth comprises a proximal part joined tothe first member on the surface of the first member, and a distal partdirectly adjacent to the proximal part and tapering to a tip of the eachof the teeth, the proximal part and the distal part having differentdegree of taper from each other.